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© Fraunhofer IFAM
EV Core Technologies and Fraunhofer System Research for Electromobility
(FSEM)
Dipl.-Ing. Felix Horch ∙ Thailand / Bangkok ∙ 2016-04-26
Driving Electric
Innovative batteries, cable-free charging
and cost-efficient drive systems are to help
improve the performance of future
generations of the electric automobile.
© Fraunhofer IFAM
fh, 26.04.2017, Folie 2
FRAUNHOFER-GESELLSCHAFT
FRAUNHOFER IFAM
© Fraunhofer IFAM
fh, 26.04.2017, Folie 3
Fraunhofer fields of research
Health and Environment
Communication and Knowledge
Production and Supply of Services
Mobility and Transport
Energy and Resources
Security and Protection
© Fraunhofer IFAM
fh, 26.04.2017, Folie 4
The Fraunhofer-Gesellschaft at a Glance
The Fraunhofer-Gesellschaft undertakes applied research of direct utility to private and public enterprise and of wide benefit
to society.
24,500 staff
More than 70%
is derived from contracts with industry
and from publicly financed research
projects.
Almost 30%
is contributed by the German federal and
Länder Governments.
69 institutes and research units Fin
ance v
olu
me
€2.1 billion
2016
Contr
act
Res
earc
h
€1.9
billion
Major infrastructure
capital expenditure and
defense research
© Fraunhofer IFAM
fh, 26.04.2017, Folie 5
Executive Board of the Fraunhofer-Gesellschaft
Prof. Dr.-Ing.
Reimund Neugebauer
President, Corporate
Policy and Research
Management
Prof. (Univ. Stellenbosch)
Dr. Alfred Gossner
Executive Vice
President Finance,
Controlling and
Information Systems
Prof. Dr.
Alexander Kurz
Executive Vice
President Human
Resources, Legal
Affairs and IP
Management
Prof. Dr.
Georg Rosenfeld
Executive Vice
President Technology
Marketing and Business
Models
© Fraunhofer IFAM
fh, 26.04.2017, Folie 6
Pooling expertise
Fraunhofer Alliances
Adaptronics
Ambient Assisted Living
Big Data
Digital Cinema
Energy
Food Chain Management
Additive Manufacturing Cloud Computing
AdvanCer
Nanotechnology
Simulation
Photocatalysis
Polymer Surfaces
Cleaning Technology
Water Systems (SysWasser)
Traffic and Transportation
Vision
AutoMOBILE Production
Lightweight Structures
Embedded Systems
Battery
The Fraunhofer Alliances facilitate customer access to the services and
research results of the Fraunhofer-Gesellschaft. Common points of contact for
groups of institutes active in related fields provide expert advice on complex
issues and coordinate the development of appropriate solutions.
Building Innovation
Space
© Fraunhofer IFAM
fh, 26.04.2017, Folie 7
FRAUNHOFER IFAM AT A GLANCE
Fraunhofer-Institut IFAM
Founded in 1968,
since 1974 at Fraunhofer
locations in Bremen
and Dresden
Research groups in
Oldenburg, Stade and Wolfsburg
609 employees
46,9 Mio. € annual budget (2016)
© Fraunhofer IFAM
fh, 26.04.2017, Folie 8
FRAUNHOFER IFAM – LOCATIONS AND TOPICS
»Fraunhofer-Linien«
Institute directors
Prof. Dr.-Ing. habil. Matthias Busse
Prof. Dr. Bernd Mayer
DRESDEN Metal powder technology STADE Automation and Production Technology for
FRP
OLDENBURG Electrical Energy Storage
Systems
WOLFSBURG production technologies for
light weight materials
© Fraunhofer IFAM
fh, 26.04.2017, Folie 9
DEPARMENT ELECTRIC DRIVES
Field of activity
electromagnetic and
thermal design /
simulation of electric
drives
mechanical design and
construction
software developement,
vehicle control and ECU
design for drive inverters
APPLICATIONTESTINGPRODUCTIONDEVELOPMENT
production of
components for electric
drivetrain
development of
production technologies
design and casting
production of cast coils
build-up of prototypes
performance tests
functional safety
fault tolerant drives
Testing and
benchmarking of drives
systems
vehicle integration of
components
build-up of demonstrator
vehicles
industrial and servo
drives
© Fraunhofer IFAM
fh, 26.04.2017, Folie 10
OFFERS
Electric Drives
development
Electromagnetic
design
Thermal management
Technical consulting
drive design
ECU development
Development of
production
technologies for
electric drives
Production and
initialization of
prototypesproduction
Performance tests
Evaluation and
benchmarking
testing
Integration and testing
of electric drive
systems in application
(i.e. BEV, PHEV)
application
© Fraunhofer IFAM
fh, 26.04.2017, Folie 11
FRAUNHOFER IAO
© Fraunhofer IAO, IAT Universität Stuttgart
Founded: IAO – 1981
IAT – 1991
Director: Prof. Dr.-Ing. Wilhelm Bauer
Budget: 34.3 million euros*, of which
34.8 % are generated from industry
Staff: about 560 employees*
* Figures from 2015, including IAT University of Stuttgart
IAO Institut für Arbeitswirtschaft und Organisation (Institute of
Industrial Engineering)
www.iao.fraunhofer.de/lang-en
IAT Institut für Arbeitswissenschaft und
Technologiemanagement (Institute of Human Factors)
www.iat.uni-stuttgart.de
Fraunhofer IAO and University of Stuttgart IAT
Applied research for our customers´ benefit
Fraunhofer IAO collaborates closely with IAT at University of Stuttgart
© Fraunhofer IAO, IAT Universität Stuttgart
Service & Human
Resources Management
Corporate Development
& Work DesignEngineering Systems
Information &
Communication Technology
Technology &
Innovation Management
Mobility & Urban
Systems Engineering
Six Business areas
People are at the heart of our research
© Fraunhofer IAO, IAT Universität Stuttgart
Mobility and Urban System Engineering
Solutions for sustainable cities, intelligent mobility and flexible work
Immersive Engineering Lab
Mobility Innovation Lab Micro Smart GridNew Vehicle Concept
Shared Systems´ DesignSustainable Mobility Concepts Urban Systems Engineering
Cloud Laboratory/m-LabVehicle Interaction Lab
© Fraunhofer IAO, IAT Universität Stuttgart
Urban Logistics
Smart District
User behavior/
Transformation
Prototyping
Urban Innovation
& Governance
Technology
Management
Energy & Charging
infrastructure
Mobility Concepts
Fleets
Value-chain-
system
Business models
Data Mining
Research areas in our business unit
Mobility and Urban Systems Engineering
© Fraunhofer IFAM
fh, 26.04.2017, Folie 16
MOTIVATION
WHY ELECTROMOBILITY?
© Fraunhofer IFAM
fh, 26.04.2017, Folie 17
Thinking Ahead – Why Electromobility?
Relevant megatrends up to 2050
HealthEnergy and resources Environment and climate protection
Knowledge societyLife/work cycle
Demographic changeUrbanisation
Globalisation
Mobility
© Fraunhofer IFAM
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Why is there a need for E-mobility, efficient storage and distribution of “green” electricity?
Finite oil and gas reserves
Ambitious targets to reduce CO2 emissions
„Clean“ electricityMegacities
Population growth
Increasing environmental
pollution in cities
Motorization in newly
industrializing countries
Volatile oil prices
© Fraunhofer IFAM
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Demand for mobility in emerging markets (2012)
So
urc
e:
BC
G s
tud
y2
01
2, h
ttp
://d
e.s
tatista
.com
© Fraunhofer IFAM
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29,017 electric cars sold in
Europe in the first half of
2014.
1st place: Nissan Leaf with
7,109 units
2nd place: Tesla Model S
with 5,330 units
(Avere France)© BlankMap-World-alt
By 2017: Fleet of
Chinese government
with min. 30% electric
cars(Xinhua.net)
By March 2016:
100 hydrogen fuel
stations in Japan
USD 50 million from
U.S. Department of
Energy
for the development of
new technologies(Energy.gov)
Overview of the Current Market Situation
© Fraunhofer IFAM
fh, 26.04.2017, Folie 21
E-Mobility Regions in Germany
Model Region BMVI
Store Window E-Mobility Federal Government
Region with Model Project of BMVI
http://starterset-elektromobilitaet.de/info
© Fraunhofer IFAM
fh, 26.04.2017, Folie 22
NEV infrastructure in Germany: Example Berlin
About 400 (semi-)public charging points available
in Berlin
1,800 public charging points by the end of March
2017 in Germany
New innovative technology from Ubitricity reduces
cost for charging points from around € 10,000 to
€ 300
Smart cable with integrated mobile metering
unit
Compact system socket allows installation on
a wall or integrated into a light mast
Source: Ubitricity
© Fraunhofer IFAM
fh, 26.04.2017, Folie 23
NEV infrastructure in Germany: Example Lathen
Dynamic inductive charging test track installed in
Lathen (German maglev location)
Pick-up system with induction coil in the vehicle
Primary coils in the street
Air gap between pick-up and street is
about 15 cm
System transfers up to 60 kW
Source: Fraunhofer IFAM
Source: Fraunhofer IFAM
© Fraunhofer IFAM
fh, 26.04.2017, Folie 24
NEV infrastructure in Germany: Example Bremen
Fraunhofer IFAM operates an innovative
combined charging station
system consisting of 3 modules
Solar panels for charging the redox
flow container
Redox flow container with
100 kWh
Charging station with 6 charging points
Source: Fraunhofer IFAM
© Fraunhofer IFAM
fh, 26.04.2017, Folie 25
E-Mobility in Germany today
Public transport
(besides Railway and Tram)
www.berliner-verkehrsseiten.de
www.stadtwerke-osnabrueck.de
www.braunschweig.de
© Fraunhofer IFAM
fh, 26.04.2017, Folie 26
E-Mobility in Germany today
Motorized individual transport
NISSAN
www.focus.de
K. Jahn
K. Jahn
www.bosch.-de
© Fraunhofer IFAM
fh, 26.04.2017, Folie 27
So
urc
e:
EU
CA
R / C
ON
CA
WE
Petrol
Diesel
Hybrid diesel
Hybrid petrol
Greenhouse gas emissions [g CO2eq / km]
Energy consumption well-to-wheel [MJ / 100 km]
Electric vehicles
with battery
Operation with electricity
from 100% renewable
energy sources
Electric vehicles with battery
Operation with electricity from 100%
EU mix
Emission-free mobility with fuel cells and battery
© Fraunhofer IFAM
fh, 26.04.2017, Folie 28
Purpose design
Development of a vehicle for a certain purpose
Tomorrow’s cars must …
… use up a minimum of natural resources
during manufacture,
… have a low fuel consumption or must be
driven by electricity, and
… require very little maintenance.
Purpose design for e-mobility means:
Lightweight construction
Special package taking into account the
particular demands of the single new
components in the vehicle development
Energy-optimized (electric drive train,
ancillary components)
Meaningful material mix (application of new
materials). Fraunhofer IFAM car sharing concept car
© Fraunhofer IFAM
fh, 26.04.2017, Folie 29
For example:
Internal combustion engine
Tank system
Transmission
Clutch
Exhaust system
…
Problem:
Changes also in the
supply industry
HOW WILL THE AUTOMOTIVE INDUSTRY CHANGE IN THE UPCOMING YEARS?
© Fraunhofer IFAM
fh, 26.04.2017, Folie 30
Time
Cylinder head Transmission housing
Injection pump
Exhaust manifold
Co
mp
on
en
ts o
f in
tern
al
co
mb
usti
on
en
gin
e
Battery case
Electric motor housing […]
Structural components
Co
mp
on
en
ts o
f e
lec
tric
tra
cti
on
mo
tor
CHANGE IN THE PRODUCT PORTFOLIO
© Fraunhofer IFAM
fh, 26.04.2017, Folie 31
Future of E-Mobility
www.berliner-verkehrsseiten.de
www.stadtwerke-osnabrueck.de
www.braunschweig.de
NISSAN
www.focus.deK. Jahn
K. Jahn
www.bosch.de
© Fraunhofer IFAM
fh, 26.04.2017, Folie 32
Future Development until 2030
Continuous increase of power and
energy density of traction batteries
Reduction of costs and weight
Increasing lifetime
Standard Range of E-cars > 500km
without charging (today: > 200km possible)
Charging power on public stations:
up to 250kW (today: 120kW possible)
Bi-directional charging of e-cars will be
standard
using traction battery as storage device
charging/discharging when car is connected
to grid
inductive charging (stationary and dynamic)
common in public areas
© Fraunhofer IFAM
fh, 26.04.2017, Folie 33
FRAUNHOFER SYSTEM RESEARCH FOR ELECTROMOBILITY
FSEM
© Fraunhofer IFAM
fh, 26.04.2017, Folie 34
Main objectives
address specific questions relating to
development and industrialization of
technologies for electromobility by meeting
the needs of partners from industry
expand the know-how, competencies and
networks on the production of actual
components for electric vehicles
develop innovative technologies and
components for hybrid and electric vehicles
which are to be industrialized together with
commercial partners.
further promote the concept of systems
research by cooperation of various
Fraunhofer institutes.
Fig.: locations of 16 Fraunhofer-Institutes
Freiburg
Stuttgart
Pfinztal
DarmstadtErlangen
Nürnberg
Oberhausen
Aachen
Itzehoe
Bremen
ChemnitzDresden
Ilmenau
Kassel
© Fraunhofer IFAM
fh, 26.04.2017, Folie 35
PROJECT LAYOUT
Collaboration within a internal project,
funded by Fraunhofer-Gesellschaft,
total budget of
12 Mio. €
three technological cluster
Drive Train / Chassis
Battery / Range Extender
Construction / Infrastructure
duration of the project:
2013 to 2016
project management
Prof. Dr.-Ing. Matthias Busse
(speaker, IFAM)
PD Dr.-Ing. Welf-Guntram Drossel
(deputy speaker, IWU)
air-cooled wheel
hub motor
air-cooled
power
electronics
chassis
compact range
extender
lightweight
battery system
battery
management
system
cool mobile
battery
crash safety
battery / range
extender
fuel cell
system design
fuel cell
range extender
Li-Booster
FRC body
elements
autonomous
driving
highly
integrated floor
assembly
interior acoustics
bi-directional
inductive power
transfer
CNT heating
communication
gateway
powertrain /chassis
construction / infrastructure
battery / range extender
© Fraunhofer IFAM
fh, 26.04.2017, Folie 36
CLUSTER »DRIVE TRAIN / CHASSIS«
Technological highlights
development of an air-cooled, lightweight
and cost-effective drive system for
personal urban mobility
air-cooled wheel hub motor using
casted aluminum coils (IFAM)
active chassis control via magneto-
rheologic damper system; especially
designed rims optimized for air cooling
during operation (LBF)
air-cooled multi-level DC/DC-converter
and also air-cooled traction inverter using
3H-topology
Bild: Technologien des Clusters Antriebsstrang /
Fahrwerk
LBF
IISB
IFAM
© Fraunhofer IFAM
fh, 26.04.2017, Folie 37
INTRODUCTION
Motivation and general idea
Motivation
Increase slot filling factor and improve thermal
characteristics
Enhance power and torque density of
electrical machines
Reduce material and production cost
Develop production processes for high-volume
production of electric drives
General idea:
Realization of the casting process using a flat
conductor, spiral-geometry
Utilizing the inherent advantages of the casting
process, such as:
Geometrical flexibility and precision
Mass production capability
Integrability in the design process
Geometry of cast coil compared to
wound copper coil
© Fraunhofer IFAM
fh, 26.04.2017, Folie 38
INTRODUCTION
Process sequence
Coil is designed with flat conductor
arrangement
Afterwards, geometry is stretched to allow
insertion of a mould for casting process
Gatings are added to each conductor to
provide melted metal in casting process
Depending on geometry and quantity, different
casting processes can be used:
Investment (“lost-wax”) casting
Die-Casting
Lost Foam casting
Insulation is realized after removal of gatings
After insulation process, coil is compressed
and mounted on lamination stack
Casting process &
removal of gatings
Stretching & adding of
gating
Insulation process
Designed coil geometry
Gatings
© Fraunhofer IFAM
fh, 26.04.2017, Folie 39
ADVANTAGES OF CAST COILS
Geometrical Advantages
Characteristics of casting technology:
Precise reproduction of designed geometrywith low tolerances
Variable cross-sectional geometry of the conductor
Flat conductors with variable width and height
in each turn:
Slot filling factor up to 80 %
Bending radius not required
Further advantages due to variable conductor shape:
Realization of innovative cooling concepts
Integration of cooling channels in the conductors possible
Reduction of thermal hotspots in end winding possible
Top: Cross sectional
geometry of cast coils
Right: Variable
height and width of
conductor shape α
AL
bz
r0
~~
h0
hi
ri~~
© Fraunhofer IFAM
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ADVANTAGES OF CAST COILS
Electromagnetical Advantages
Slot filling factor up to 80 %:
Reduced resistance compared to wound coils with
same slot dimensions
Reduction of the slot height possible to reduce
machine weight and material cost
Reduced current displacement effects:
For a given turn number, flat conductor alignment
is optimal in terms of electro-magnetic behaviour
Effects of current displacement are significantly
reduced compared to single stranded round wire
In most applications, no parallel strands required
No bending radius at end winding :
reduction of eddy current effects in conductive
housing (bearing shields, water jacket) due to less
leakage field in the overhang
Higher utilisation of available space
Ohmic loss distribution at 300 Hz of
round and cast coil in a slot
Resistance Cast coils Round wire
100 Hz 1.04 1.08
250 Hz 1.22 1.50
Tab.: Resistance-factor with different
frequencies
© Fraunhofer IFAM
fh, 26.04.2017, Folie 41
ADVANTAGES OF CAST COILS
Thermal Advantages
Flat conductor arrangement of cast coils reduces thermal resistance to lamination stack
Because of low tolerances in casting process, slot insulation thickness can be reduced
Measurement results
Thermal resistance was estimated by
measurements with similar geometry
Thermal resistance of cast coil is decreased
by 80 % compared to wound coil
Current density of up to 24 A/mm² possible in steady state operation
be
tte
r
Measured thermal resistance to lamination stack
of different coils in comparison
180 °C
20 °C
Temperature distribution in a cooled wound coil
(J=12 A/mm²) and a cast coil (J=18 A/mm²)
Combination of high slot filling factor and
excellent thermal behaviour allows to
double the current density per slot area
© Fraunhofer IFAM
fh, 26.04.2017, Folie 42
MATERIAL SELECTION
Aluminum vs. Copper
High slot filling factor allows to replace wound copper winding by cast aluminum winding with the same resistance
Advantages using Aluminum:
With the same resistance and installation place, a cast aluminum winding is 50% lighter and 86% cheaper than a conventional copper winding
Inorganic coating processes can increase lifetime and allow for higher operating temperatures
Due to its lower melting temperature, aluminum is suitable for highly productive casting processes, e.g. high-pressure die casting
Fig.: Normalized weight, resistance and cost of
wound copper, cast copper and cast aluminum
coils using the same slot area
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
Normalized
Resistance
Normalized Weight
Normalized Cost
Wound Copper 1 1 1
Cast Copper 0.65 1.6 1.6
Cast Aluminum 0.99 0.49 0.14
No
rmal
ize
d V
alu
es
In large scale production, aluminum offers
a combination of cost reduction and
power density improvement
© Fraunhofer IFAM
fh, 26.04.2017, Folie 43
APPLICATION EXAMPLES
A: Water jacket cooled motor for Hybrid Electric Vehicle
In collaboration with VW Kassel, a prototype
machine for a hybrid electric vehicle motor was
built up
Cast copper coils, 0.8 mm conductor height,14
turns
A slot filling factor of 72% was reached in
prototypes, considering all tolerances; up to
80% are reachable in serial production
Test bench results:
In low speed operation, the continuous output
torque is increased by up to 42%
The efficiency rises by >1% in continuous
operation
In very high-speed region (>900 Hz operating
frequency), efficiency goes down due to
effects of current displacement
Bot.: Test bench results for max. continuous
operation
Stator and cross-sectional view of cast coil
Source: C. Junginger: Design, Integration and Measurement of a Hybrid Machine with Cast Coils, EDPC 2014
+42%
© Fraunhofer IFAM
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APPLICATION EXAMPLES
B: Air-Cooled Wheel Hub Drive
For an air-cooled wheel hub motor, an electric
drive system was equipped with cast
aluminum coils
Use of aluminum reduces motor-weight
Inorganic coating with minimized thickness for
insulation
High slot filling factor and good thermal
connection allows power density comparable
to conventional water jacket cooled
applications
Drive System Data:
Permanent magnet synchronous machine
with 36 Slots and 30 poles
Peak Torque: 400 Nm
Test bench measurements currently ongoing
© Fraunhofer IFAM
fh, 26.04.2017, Folie 45
APPLICATION EXAMPLES
C: Direct-cooled coil with integrated cooling channels
General idea:
Integration of axial cooling channels in the conductors
U-shaped conductors, upper and lower side of each conductor form cooling channel
Cooling channels reach from end winding to end winding, allowing cooling fluid to flow through the machine in axial direction
Results of preliminary tests:
Current densities up to 100 A/mm² can be reached, compared to 12 A/mm² in conventional systems with water-jacket cooling
Power and torque density can be increased significantly
Top: CAD-model of coil with integrated cooling
channels
Bot.: Prototype coil
Institut für Antriebssysteme
und Leistungselektronik
Institut für Antriebssysteme
und Leistungselektronik
Cooling channels
Lamination stack
Coil
© Fraunhofer IFAM
fh, 26.04.2017, Folie 46
Cluster »Battery / Range Extender«
technological highlights
development and testing of a battery
management system with active cell
balancing (IIS)
advanced manufacturing technologies
regarding lightweight construction and
efficiency (ILT)
characterization and optimization of joining
technologies using reinforced organic
sheets and metal components, e.g. for
battery housing (ILT, IWM)
development of a high-power battery
system »Li-Booster« (ISIT)
range extender module for light-duty
commercial and municipial vehicles, that
provides electric drive and necessary
hydraulic energy (IVI) Fig.: module for leightweight battery system
© Fraunhofer IFAM
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- Reliability, -
Acceptance
- cost, quality,
safety
Power / Energy ?
Wh / kg ?
Wh / L ?
Wh / L ?
Volume ?
Lifetime?Challenge for
future batteries
Mass ?
Wh /kg?
Material research and processing are the key for better batteries !
Electrical energy storage is central for a lot of applications
© Fraunhofer IFAM
fh, 26.04.2017, Folie 48
Electrical energy storage - Technologies
© Fraunhofer IFAM
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Roadmap Lithium Ion Batteries
Improved safety, reduced cost of conventional cell chemistry
Big step for energy density new cell chemistry & new manufacturing
technologies
contineously adjustment of
convential manufacturing
process
require new technologies for
production & manufacturing
© Fraunhofer IFAM
fh, 26.04.2017, Folie 50
New kind of manufacturing process
solvent free technology
e.g. shape technology,
Challenge:
Development of appropriate new
production technology
Liquid electrolyte based: Solid electrolyte based:
Conventional manufacturing technology
solvent based technology
Extensive, dry room
Challenge:
Optimize quality, production cost,
efficiency
Battery cell manufacturing
© Fraunhofer IFAM
fh, 26.04.2017, Folie 51
Fraunhofer IFAM: Electrical Energy Storage
Based on IFAM competences in Powder technology, Surface
Technology, Adhesive Bonding Technology
Processing and manufacturing from powder to battery cell
Electrode processing and design for batteries (thick
film, thin film, shape technology)
Cell assembling and cell design
Materials und characterisation
In- situ techniques
Process and manufacturing for next generation batteries!
© Fraunhofer IFAM
fh, 26.04.2017, Folie 52
CLUSTER »CONSTRUCTION / INFRASTRUCTURE«
Technological highlights
efficient and lightweight construction
of body structures with extensive use
of functional integration, e.g. a
thermal management integrated in
the floor (1)
portable device for development of in
car acoustics (2)
innovative approach for a panel
heating using CNT (3)
communication gateway and Car2X
system for inductive charging (4)
autonomous driving: hard- & software
development, object detection (5)
Fig.: technological highlights
1
2 3
4
5
© Fraunhofer IFAM
fh, 26.04.2017, Folie 53
FRAUNHOFER PROJECT CENTER WOLFSBURG
© Fraunhofer IFAM
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Fraunhofer Project Center Wolfsburg
Strategy
large scale production of application-oriented hybrid light weight
structures
collaboration of several Fraunhofer institutes with further
research facilities such as Braunschweig University of
Technology
close collaboration with industrial partners such as Volkswagen
AG
system oriented solutions
© Reuters
© Fraunhofer IFAM
fh, 26.04.2017, Folie 55
Fraunhofer Project Center Wolfsburg
Open Hybrid LabFactory e.V.
development of production technologies for
light weight materials
development of a full process chain
including recycling for multi material light
weight parts with focus on automobil
industry requirements
Siempelkamp
multifunctional press
pressing force 2500t
Engel
hybrid injection moulding press
clamping force 3600t
Karl Mayer
textile machine
©Siempelkamp ©KarlMayer ©Engel
© Fraunhofer IFAM
fh, 26.04.2017, Folie 56
Fraunhofer Project Center Wolfsburg
»Textile manufacturing chain«
development of
production technologies
for semi finished textiles
near net shape,
semi finished
textilesmaterial development
calander direct impregnation
Life Cycle Analysis and Recycling
surface
pretreatment
weaving
machine
thermoplastic-
like processable thermosets
fiber spraying
© Fraunhofer IFAM
fh, 26.04.2017, Folie 57
hybrid materials with
metallic matrices
Fraunhofer Project Center Wolfsburg
»hybrid materials with metallic matrices«
low pressure casting
deep drawing
injection moulding
part design
and simulation
process simulationdesign of
manufacturing tools
near net shape,
semi finished
textiles
Life Cycle Analysis und Recycling
surface pretreatment
© Fraunhofer IFAM
fh, 26.04.2017, Folie 58
Fraunhofer Project Center Wolfsburg
»Components for electric vehicles«
component design
hybrid materials with metallic
matrices
near net shape,
semi finished textiles
process design
Components for
electric vehicles
integration
of functions
Life Cycle Analysis und Recycling
© Thomas Ernsting
smart
manufacturing
© Fraunhofer IFAM
fh, 26.04.2017, Folie 59
SMART MANUFACTURING
© Fraunhofer IFAM
fh, 26.04.2017, Folie 60
Electromobility: Smart Mobility combines Smart Manufacturing
High Tech for low cost
Combining high tech approaches with smart production and manufacturing
technologies and materials
Bringing down costs via automation and digitization
High Efficient and compact electric drives
Specific development of electric drives for application
(i.e. eletric busses, BEV)
Focus on efficiency at system level and compact design
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Metal Additive Manufacturing @ Fraunhofer IFAM
Electron Beam Melting (EBM)
3D Metal Printing -Screen Printing approach (3DMP)
Laser Beam Melting (LBM)
3D Metal Printing -Binder Jetting approach (3DP)
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Modular Manufacturing Platform - Functional Printing
Processes: Screenprinting, InkJet,
Aerosol Jet, Dispensing,
Pad printing, sintering
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Modular Manufacturing Platform - Functional Printing
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Printing on 3d-parts:
Printing sensors, actors,
and heating sructures on
complex shaped parts
High flexibility of the
process concerning
geometry of the printed
structures and the
substrates
New applications
Printed heating structure on glass cylinder
Sensor Integration on 3d printed parts
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© C. Bockenheimer, Airbus Deutschland GmbH: SMIST – Structural Monitoring with Advanced Integrated Sensor Technologies – Aeronautic Days, Vienna, 19.-21.06.2006
Printed strain gauges for Structrual Health Monitoring Application examples
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Temperature sensor Interdigital structures
Temperature sensor on
flexible foils
Printed electronics and printed sensor structures
Resistors, capacitors, circuit
boards, …
Conductive traces on glass
Magnetic structures for
position sensors
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Autonomous material and process flow
Embedded RFIDs enhance conventional castings to
communicate with machinery and process chains
Embedded RFID is „enabler“ for »Industrie 4.0 «
in tomorrow‘s foundry industry
RFID identification for „Industrie 4.0“ [Industry 4.0]
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RESEARCH TOPICS
PROJECT EXAMPLES
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Efficient heating for electric cars
If you don‘t want to freeze in your
electric car, you have to make a few
concessions, because heating devours
a substantial portion of power supply.
Fraunhofer researchers will exhibit the
demo model of a highly energy-efficient
heating system for electric cars at the
IAA: a coated film that produces a
broad, radiant heat.
© Fraunhofer IPA
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Circuits and sensors direct from the printer
Printers are becoming more
and more versatile.
Now they can even print
sensors and electronic
components on 2D and 3D
substrates.
A new, robot-assisted
production line allows the
process to be automated.
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How we want to live in 2053
As part of the “Shaping Future“ research
project, Fraunhofer researchers have
developed an original participatory
foresight methodology with which
laymen can describe their future
technology requirements and share
them with scientists.
Initial results show that people want to
have technologies that improve their
mental and physical capabilities, protect
their privacy and store and transport
emotions.
© Fraunhofer IAO
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JEC 2016: Rapid and energy-efficient production of lightweight components
When consolidating carbon fiber reinforced plastics (CFRP), individual layers of
fibers and plastic connect to each other under pressure and high temperatures to
form a homogeneous plate.
Fraunhofer researchers have developed a method which is fast and energy
efficient, and which is also suitable for smaller quantities as well as high-
temperature plastics: CFRP is directly irradiated in a vacuum by infrared
radiation.
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Electric cars: batteries with brains
The battery is the heart of the electric
car. Fraunhofer researchers have
developed an energy storage device
which is significantly more cost-effective
over the entire life cycle in comparison
with previous models.
If one of the more than one hundred
battery cells is defective, it can be
replaced easily. Until now, the entire
battery had to be replaced.© Fraunhofer IPA
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Solar vehicle charging at home
Owners of home photovoltaic systems will soon be able to make their
households even more sustainable, because PV power is also suitable for
charging personal electronic vehicles.
A home energy management system created by Fraunhofer researchers
incorporates electric vehicles into the household energy network and creates
charging itineraries.
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Heating with the sun
Solar-Active-Houses heat themselves
using heat collectors and water tanks.
However, no one had conducted an
objective assessment of how efficiently
they do so.
Fraunhofer researchers put some of
these solar houses to the test, identified
where there was room for improvement
and laid the scientific groundwork for
this housing concept.© Fraunhofer ISE
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A flexible solution for secure IT in cars
Today, almost everything in your car is
managed by an electronic control unit
(ECU). The problem is that these
minicomputers are increasingly coming
under attack.
Fraunhofer researchers have now
developed a platform that makes it
possible to flexibly install secure devices
in a way that is based on open and
vendor-neutral hardware and software
standards.© Fraunhofer SIT
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Fast charging electric bus does overtime
Electric buses are an eco-friendly
alternative to diesel.
With several project partners,
Fraunhofer researchers have developed
a concept to swiftly recharge buses
while they operate routes. System
testing in Dresden has been underway
since November 2015.
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Safe production in Industry 4.0
Production facilities and components of
Industry 4.0 are linked to the Internet,
networked with each other, and thus
open to attack.
Using an IT security laboratory,
Fraunhofer researchers offer a test
environment in order to simulate attacks
on this network and to detect any gaps.
They will unveil the possibilities at this
year‘s Hannover Messe.
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Vehicle body made from cotton, hemp, and wood
Carbon and glass fibers reinforce
synthetics so that they can be used for
vehicle body construction. But in this
regard, there is an abundance of
potential found in natural fibers –
obtained from hemp, cotton, or wood.
If you combined bio-based textile and
carbon fibers, you can obtain extremely
light yet very sturdy components.
© Fraunhofer WKI / Manuela Lingnau
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Electric cars without drivers
EVs will park independently in the future
and will also be able to find the next
charging station without a driver.
Researchers are working on electric
cars that can travel short distances
autonomously. On the basis of cost-
effective sensors, they are developing a
dynamic model that perceives the
environmental situation.
© Fraunhofer IPA
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Charging electric cars efficiently inductive
We already charge our toothbrushes
and cellphones using contactless
technology.
Researchers have developed a
particularly efficient and cost-effective
method that means electric cars could
soon follow suit.
© Fraunhofer IISB
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Nano-supercapacitors for electric cars
Innovative nano-material based supercapacitors are set to bring mass market
appeal a good step closer to the lukewarm public interest in Germany. This
movement is currently being motivated by the advancements in the state-of-the-
art of this device.
© Fraunhofer IPA
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Smart grid for electric vehicle fleet
Being able to charge up to 30 electric
cars at once requires some ingenious
energy management. Researchers are
incorporating a mix of renewables into
the design of a smart grid for Germany’s
largest charging station.
© Victor S. Brigola/Fraunhofer IAO
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Car manufacturing – fast track towards mass production
New models of automobiles are
initially manufactured in a pilot
production run.
A new procedure now makes it
possible to transfer the
parameters applied there directly
to serial production.
© Fraunhofer IWU
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Making cars that are lightweight and crash-safe
Lightweight or crash-safe – must it
always be a trade-off for auto makers?
The answer is no. With a new
lightweight construction technology,
researchers are making it possible to do
both. The result is less fuel consumption
and lower manufacturing costs.
© Fraunhofer IWS
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CONTACT
Dipl.-Ing. Felix Horch
Head of department
Electric Drives
Fraunhofer Institute for Manufacturing
Technology and Advanced Materials IFAM
Wiener Straße 12 | 28359 Bremen | Germany
Telefon + 49 421 2246-171 | Fax -300
www.ifam.fraunhofer.de